So my little ones are going to be Sheriff Woody and Jessie from Toy Story. The biggest challenge for this was trying to figure out hats. My little ones are 3 years old and 9 months. So to find a hat that fit and they'd keep on their heads was going to be a challenge.
I decided to make them from foam.
First, you'll need the measure the head. Then cut out 3 pieces. You'll need the rim, the rise and the top.
First, fold the rise in half and stitch it. Then place the top on the rise and stitch it down. I used my sewing machine. It worked out fairly well, not perfect, but that is life.
Next, place your rim on your rise and pin it in place. Since it is foam, pinning is difficult, but this helps it not move as you sew. Now stitch it down. Good luck ,it isn't easy!